Plastic water meter with metal threads

ABSTRACT

Embodiments of the present invention generally relate to flow meters and more particularly to improved plastic water flow meters for commercial or residential use. In various embodiments, a plastic water meter is provided that may include metal threads for connecting the water meter to a water system. In particular, the plastic water meter may include at least one spud that is shaped to receive and engage a plastic spud insert, in which the plastic spud insert may include a metal ring with a threaded outer surface. The plastic spud insert may include an annular lip portion extending outwardly to discourage removal of the metal ring when the spud insert is engaged with the water meter. Furthermore, the plastic spud insert and the inner surface of the metal ring may have complementary circumferential profiles to discourage relative rotation between the metal ring and the spud insert.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.12/947,272, filed Nov. 16, 2010, which is a continuation of U.S. patentapplication Ser. No. 12/356,240, filed Jan. 20, 2009, which claims thebenefit of U.S. Provisional Patent Application Ser. No. 61/022,088,filed Jan. 18, 2008, which are all hereby incorporated herein in theirentirety by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to flow meters and moreparticularly to improved plastic water flow meters for commercial andresidential use.

2. Description of Related Art

Water meters are designed to measure the volume of water usage or thevolume of water flow. Water meters can be used in both commercial andresidential settings, and they can be utilized at a water source, apoint of water usage, or anywhere in between. Typically, water metersare manufactured from one of two types of material: metal or plastic.The trend with water meters is towards the use of plastic meters, asopposed to metal meters. One reason for this trend is that manyjurisdictions now require zero lead content in the water supply andaccordingly, meters in contact with the water supply also need to havezero lead content. Plastic meters satisfy this zero lead contentrequirement.

Generally, a water meter possesses threaded inlets and outlets tofacilitate the connection between the water meter and the water system.Plastic water meters generally utilize plastic threads, but watersystems typically employ metal threads for the mating connections withwater meters. Accordingly, the plastic threads have a tendency to stripor cross thread during installation. Therefore, there is a desire for aplastic water meter with improved inlet and outlet connectivity.

BRIEF SUMMARY OF THE INVENTION

The following summary is not an extensive overview and is not intendedto identify key or critical elements of the apparatuses, methods,systems, processes, and the like, or to delineate the scope of suchelements. This Summary provides a conceptual introduction in asimplified form as a prelude to the more-detailed description thatfollows.

In one embodiment of the present invention, a water meter is provided.The water meter may include a plastic top cover defining an interiorcavity shaped to accept a metering device, in which the top coverfurther defines at least one spud defining a bore in communication withthe interior cavity; a metering device positioned in the interiorcavity; a bottom cover engaging the top cover and enclosing the meteringdevice within the interior cavity; and at least one connector assemblyengaging the at least one spud. The connector assembly may include aplastic spud insert having a first end and a second end, in which theplastic spud insert may include an engagement portion proximate thefirst end engaging the spud, an annular lip portion positioned proximatethe second end and extending outwardly, and a collar portion having acircumferential profile and positioned intermediate the engagementportion and lip portion. The assembly may also include a metal ringhaving an inner surface and outer surface, in which threads may beformed on the outer surface and the inner surface may have a profilecomplementary with the profile of the collar, the metal ring may bepositioned proximate the lip portion with the inner surface engaging thecollar portion, and the circumferential profile of the collar portionand the complementary profile of the metal ring may be configured todiscourage relative relational movement. In alternative embodiments, thewater meter may include an inlet spud and an outlet spud and an inletconnector assembly and an outlet connector assembly, in which eachconnector assembly may engage its respective inlet spud or outlet spud.In such embodiments, the inlet spud may be situated approximately 180degrees opposite the outlet spud. In regard to the materials that makeupthe components of the connector assembly, the plastic top cover and/orthe plastic spud insert may be styrene, polystyrene, nylon, or glassreinforced thermoplastic, among other materials, and the metal ring maybe brass, bronze, a brass derivative, a bronze derivative, or stainlesssteel, among other materials. Furthermore, the metering device includedin the water meter may be a nutating disk displacement flow meter. Evenmore, the engagement portion of the plastic spud insert may engage thespud by a mild interference fit and may be secured to the spud by spinwelding, solvent welding, sonic welding, or by an adhesive, among othermethods. Additionally, the circumferential profile of the collar maydefine various shapes, including a shape having at least one linearsection, a shape having a plurality of linear sections, and asubstantially oval shape, among other shapes. Furthermore, the innersurface of the metal ring may engage the collar portion by a key-fitarrangement.

In another embodiment of the present invention, a connector assembly foruse with a plastic device having a spud defining a bore is provided. Theassembly may include a plastic spud insert having a first end and asecond end, in which the plastic spud insert may include an engagementportion proximate the first end configured to engage with the bore, anannular lip portion positioned proximate the second end and extendingoutwardly, and a collar portion having a circumferential profile andpositioned intermediate the engagement portion and lip portion. Theassembly may also include a metal ring having an inner surface and outersurface, in which threads may be formed on the outer surface and theinner surface may have a profile complementary with the profile of thecollar, the metal ring may be positioned proximate the lip portion withthe inner surface engaging the collar portion, and the circumferentialprofile of the collar portion and the complementary profile of the metalring may be configured to discourage relative relational movement. Thecircumferential profile of the collar may define various shapes,including a shape having at least one linear section, a shape having aplurality of linear sections, and a substantially oval shape, amongother shapes. Furthermore, the inner surface of the metal ring mayengage the collar portion by a key-fit arrangement. As for the materialsthat makeup the components of the connector assembly, the plastic spudinsert may be styrene, polystyrene, nylon, or glass reinforcedthermoplastic, among other materials, and the metal ring may be brass,bronze, a brass derivative, a bronze derivative, or stainless steel,among other materials.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 is an exploded view of a plastic water meter 10 according to oneembodiment of the present invention.

FIG. 2 is an exploded view of the housing assembly 20 shown in FIG. 1.

FIG. 3 is an exploded, cross-section view of a plastic water meter 10according to one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments of the inventions are shown. Indeed, these inventions may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout.

Various embodiments of the present invention provide improved plasticwater meters that address issues known in the art, some of which arediscussed above. FIG. 1 illustrates a plastic water meter 10 accordingto one embodiment of the present invention. This embodiment may includea water meter housing assembly 20 that may enclose a metering device 40and a strainer 50. The metering device 40 and the strainer 50 may bepositioned inside the housing assembly 20, and a bottom cover 60 and ano-ring 55 may enclose them within the housing assembly 20.

Referring to FIGS. 2 and 3, the housing assembly 20 may include a topcover 21 and two connector assemblies 24A, B. Each connector assembly24A, B may include a plastic spud insert 26A, B and a metal ring 25A, B,and one connector assembly may function as an inlet connector assembly24A and the other connector assembly may function as an outlet connectorassembly 24B. Additionally, the top cover 21 may include an integratedinlet spud 23A and an integrated outlet spud 23B. The top cover 21 andthe two spud inserts 26A, B may be made from various types of plastic orhigh-strength polymer materials, including styrene, polystyrene, nylon,or the like. In a preferred embodiment, the top cover 21 and the twospud inserts 26A, B may be composed of glass reinforced thermoplastic.Factors that may be considered when selecting a material include workingpressures of the meter, and working temperature ranges.

The top cover 21 may be substantially cylindrical in shape with anintegrated top face portion 22, although those skilled in the art willrecognize that the top cover 21 may take other shapes. The bottom of thetop cover 21 remains open, thus forming an aperture that leads to theinterior cavity 31 of the top cover 21.

Proximate the bottom of the top cover 21 may be external threads 30,which may enable the bottom cover 60 to engage to the top cover 21. Inuse, the top cover may flex outwards because of pressure in the systemthereby causing the internal threads in the top cover to be urgedagainst the complementary threads on the bottom cover. In otherembodiments, the top cover may include internal threads designed toengage external threads on the bottom cover.

One advantage of the external bottom threads 30 provided in variousembodiments of the present invention may be that external bottom threads30 are easier to manufacture than internal bottom threads. As will beunderstood by those skilled in the art, forming internal threadsrequires an insert mold, while forming external threads does not. Insome cases, an additional manufacturing step may be required to removethe internal thread mold insert, which may reduce the efficiency of themolding process.

In the illustrated embodiment, the top cover 21 may include anintegrated inlet spud 23A, through which water enters the interiorcavity 31 defined by the top cover 21, and an integrated outlet spud23B, through which water exits the top cover 21. The inlet spud 23A andoutlet spud 23B may be in communication with the interior cavity 31 ofthe top cover 21. Also, the inlet spud 23A and the outlet spud 23B maybe each designed to receive and engage a portion of the spud insert 26A,B.

Both the inlet spud 23A and the outlet spud 23B protrude substantiallyperpendicularly from the exterior of the top cover 21, with the outletspud 23B situated approximately 180 degrees around the exterior of thetop cover 21 from the inlet spud 23A. As will be understood by those ofskill in the art, the inlet spud 23A and outlet spud 23B may have arelative orientation other than 180 degrees.

The spuds 23A, B may be substantially similar to each other and may havea substantially cylindrical in shape. Each spud 23A, B defines an axialbore with a proximate orifice that opens through the wall of the topcover 21 into the interior cavity 31 of the top cover 21 and a distalorifice that opens away from the top cover 21. The proximate orifice anddistal orifice of each spud 23A, B may be substantially circular inshape. In alternative embodiments of the present invention, each spud23A, B, may not protrude from the exterior of the top cover 21, but mayinstead be an orifice in the exterior of the top cover 21.

The bores defined by the inlet spud 23A and the outlet spud 23B may beeach sized to receive a spud insert 26A, B respectively, and each spudinsert 26A, B may include an externally threaded metal ring 25A, B. Apurpose of the threaded metal rings 25A, B may be to facilitateconnection of the water meter to a water system, which generallyutilizes metal threads for the connection to the water meter. Each spudinsert 26A, B may be substantially cylindrical in shape with a boreformed therein to allow the passage of water.

Each spud insert 26A, B may include a first end proximate to the topcover 21 and a second end distal the top cover 21. Proximate the secondend of each spud insert 26A, B may be an annular lip portion or rim 29A,B that extends outwardly. Each threaded metal ring 25A, B may bepositioned proximate the annular lip portion 29A, B on the spud insert26A, B. A purpose of the annular lip portion 29A, B may be to aid inpositioning the threaded metal ring 25A, B on the spud insert 26A, B andto discourage removal of the threaded metal ring 25A, B when the spudinsert 26A, B may be engaged with the top cover 21, as will be discussedin greater detail later. Additionally, the spud insert 26A, B mayinclude a collar portion 28A, B that may have a circumferential profileand may be positioned proximate to the lip portion 29A, B. The collarportion 28A, B may be shaped to engage a complementary shaped profile ofthe inner surface of the threaded metal ring 25A, B to discouragerelative rotation between the threaded metal ring 25A, B and the spudinsert 26A, B. In one embodiment, the circumferential profile of thecollar portion 28A, B may define a shape having at least one linearsection or facet. In other embodiments, the circumferential profile ofthe collar portion 28A, B may define a shape having a plurality oflinear sections. In such embodiments, the circumferential profile maytake the shape of, for example, a triangle, square, pentagon, hexagon,or octagon. In even more embodiments, the circumferential profile of thecollar portion 28A, B may be substantially oval. In further embodiments,inner surface of the threaded metal ring 25A, B may engage the collarportion 28A, B by a key-fit arrangement.

Extending from the collar 28A, B of each spud insert 26A, B may be anengagement portion 27A, B. This engagement portion 27A, B may have acylindrical shape and may be sized to be positioned within the axialbore of a spud 23A, B. The orifice proximate the engagement portion 27A,B of each spud insert 26A, B may be substantially circular in shape andmay be substantially perpendicular to each cylindrically-shaped spudinsert 26A, B. In various embodiments, the exterior diameter of theengagement portion 27A, B of each spud insert 26A, B may besubstantially similar to the interior diameter of the axial bore of eachspud 23A, B. Thus, the engagement portion 27A, B of each spud insert26A, B fits snugly into its associated spud 23A, B. In some embodiments,there may be a mild interference fit. The spud insert 26A, B may besecured to the respective spud 23A, B using spin welding, solventwelding, sonic welding, or an adhesive. An advantage of this arrangementmay be that the metal threads do not contact the water supply andtherefore do not impact the zero lead content requirements present inmany jurisdiction.

The threaded metal ring 25A, B may be made from various types of metalsand metal alloys, including brass, bronze, brass or bronze derivatives,stainless steel, or other similar metal materials. In a preferredembodiment, the threaded metal ring 25A, B may be made of bronze.Factors that may be considered when selecting a material for thethreaded metal ring 25A, B include material strength and corrosionresistance.

In alternative embodiments, the top cover 21 may include one spud or mayinclude more than two spuds, in accordance with the present invention.In such embodiments, each spud would be similar in construction to thespuds disclosed above and would be shaped to engage a spud insert thatmay include a metal threaded ring, in accordance with the abovedisclosure.

In various embodiments, the metering device 40 may be a nutating diskdisplacement flow meter, wobble plate meter, or other metering deviceknown in the art. The metering device 40 may contain an inlet throughwhich water enters the metering device 40 and an outlet through whichwater exits the metering device 40. Referring to FIG. 3, the meteringdevice 40 may contain a nutating disk 42 mounted on a sphere 44 that is“wobbled” by the fluid flow where each “wobble” represents a finiteamount of fluid transferred. It should be understood that other types ofmetering devices may be used in connection with the present invention.

The strainer 50 may be semi-cylindrical in shape and may be designed tobe situated between the inlet spud of the top cover 21 and the inlet ofthe metering device 40. The strainer 50 may be designed to strainforeign objects from the water before the water enters the meteringdevice 40.

The metering device 40 and the strainer 50 may be positioned inside thetop cover 21 and the bottom cover 60 may enclose them within the topcover 21. The bottom cover 60 may be circular in shape and may contain atop face that may be configured to be positioned proximate to the topcover 21 and a bottom face that may be distal to the top cover 21. Thetop face of the bottom cover 60 may contain a substantially annularchannel that may be shaped and sized to engage the bottom end of the topcover 21. In particular, the width of the channel may be substantiallysimilar to thickness of the wall of the bottom end of the top cover 21.The exterior wall of the channel may include threads that are configuredto engage the external bottom threads 30 of the top cover 21 to enclosethe metering device 40 and the strainer 50 within the interior cavity 31of the top cover 21.

The bottom cover 60 may be made from various types of plastic orhigh-strength polymer materials, including styrene, polystyrene, nylon,or the like. In a preferred embodiment, the bottom cover 60 may becomposed of glass reinforced thermoplastic. Factors that may beconsidered when selecting a material include working pressures of themeter, and working temperature ranges.

The o-ring 55 may be positioned in the channel to provide a seal betweenthe top cover 21 and the cover 60. In the illustrated embodiment, thecross section of the o-ring is circular; however, other o-ring profilesmay be used in connection with embodiments of the present invention.

Many modifications and other embodiments of the inventions set forthherein will come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the inventions are not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

1. A water meter enclosure comprising: a non-metallic cover defining aninterior cavity shaped to accept a metering device; a metal ringincluding an outer surface, wherein threads are formed on the outersurface for connection of a water conduit to the ring; and anon-metallic collar, the non-metallic collar including a non-metallicannular lip contacting a distal end of the metal ring to retain themetal ring proximate the non-metallic cover.
 2. The water meterenclosure of claim 1, further comprising at least one spud connected tothe non-metallic cover and defining a bore in communication with theinterior cavity.
 3. The water meter enclosure of claim 2, wherein the atleast one spud includes at least an inlet spud and at least an outletspud.
 4. The water meter enclosure of claim 3, wherein the at least oneinlet spud is situated approximately 180 degrees opposite the at leastone outlet spud.
 5. The water meter enclosure of claim 2, wherein atleast one spud insert engages each at least one spud.
 6. The water meterenclosure of claim 5, wherein the at least one spud insert includes anengagement portion to engage the at least one spud inside the bore. 7.The water meter enclosure of claim 5, wherein the collar and the annularlip are portions of the at least one spud insert.
 8. The water meterenclosure of claim 1, further comprising a bottom cover fixedly attachedto the non-metallic cover and enclosing a metering device within theinterior cavity.
 9. The water meter enclosure of claim 8, wherein themetering device includes a nutating disk displacement flow meter. 10.The water meter enclosure of claim 1, wherein the non-metallic cover isof a material selected from the group consisting of styrene,polystyrene, nylon, and glass reinforced thermoplastic.
 11. The watermeter enclosure of claim 1, wherein the ring is of a material selectedfrom the group consisting of brass, bronze, brass derivatives, bronzederivatives, and stainless steel.
 12. A method of making a water meterenclosure, the method comprising: obtaining a metal ring, the metal ringincluding an outer surface, the outer surface including threads; andarranging the metal ring proximate a non-metallic cover, thenon-metallic cover defining an interior cavity shaped to accept ametering device, such that a distal end of the metal ring contacts anon-metallic annular lip of a non-metallic collar.
 13. The method ofclaim 12, wherein the non-metallic cover includes at least one spudconnected to the non-metallic cover and defining a bore in communicationwith the interior cavity.
 14. The method of claim 13, wherein the atleast one spud includes at least an inlet spud and at least an outletspud.
 15. The method of claim 14, wherein the at least one inlet spud issituated approximately 180 degrees opposite the at least one outletspud.
 16. The method of claim 13 further comprising the step ofconnecting at least one spud insert to each at least one spud.
 17. Themethod of claim 16, wherein the non-metallic collar and the non-metallicannular lip are portions of the at least one spud insert.
 18. The methodof claim 16, wherein each at least one spud insert is connected to atleast one spud by plastic welding.
 19. The method of claim 12 furthercomprising the step of connecting the non-metallic annular lip and thenon-metallic collar to the non-metallic cover.